Tacoma exhaust Manifold (Left) next to a lump of metal on the Right!
Below - Tacoma Exhaust manifold onto Hilux 1GR-FE 4.0 LT V6
Tacoma manifold Right Side P/N 17140-0P140 bolts up perfectly!
Tacoma manifold Left Side P/N 17150-0P140 you will also require the Tacoma Manifold stay P/N 17119-0P010
Left side Tacoma Manifold stay P/N 17119-0P010 – bolts up perfectly!
You will also need the Tacoma A/F Sensors - 89467-040 L/H and 89467-04050 R/H - you don't need to but I also replaced the O2 sensors (rear ones) 894565-04340 L/H and 89465-04350
304 Stainless Steel – 2.25” inch into 2.5” with a Bruns Stainless Steel “Tuned” length collector and equal length pipes from manifold with Stainless Steel “V” Bands and all Tig Welded
Burns Stainless Tuned Length Y Pipe 2.25” to 2.5”
Centre Muffler – Borla ProXS 40665 – 2.5” Centre in Offset out
Below Rear Muffler – Borla ProXS 40352 – 2.5” Offset in Offset out
Rear Muffler – most manufactures now place a muffler at the rear for max noise reduction
Below Rear Muffler – Borla ProXS 40352 – 2.5” Offset in Offset out
Results – Below is KW and NW – 10Kw (13.4Hp) Gain plus Massive torque gains at all RPM!
8.2% KW gain and 8.3% NW gain - to put this into prospective that's Aprox 190KW and 410NW at the flywheel
Results – Below is KW and A/F - Still heaps of fuel so will try the TRD Tacoma CAI when I have a chance as it has a larger diameter pipe where MAF Meter sits and its been reported on Tacomas to trim up the fuel and increase HP
Is it worth all this work?
Upping the Torque to 410nw makes a massive difference to drivability and fuel economy but compared to the outright numbers of Supercharging the short answer is no! But it's worth remembering that the TRD Hilux has 453nw so the result is great!
But if your like me and don't want to run a "Piggy Back ECU" you have no other power up options - Philby on Newhilux is the only guy I know smart enough to use factory software on his aftermarket TRD Supercharged SR5 Hilux
After that is it still worth it
Anyone who has driven the 1GR-FE Hilux Auto will tell you it drives like an expensive car - well I can tell you after installing the Tacoma 2009-2011 Header and Tuned Length exhaust it is on another level - its just so quite and has so much more torque!
It now holds gears much much longer including the same run with 800Kg in the back but on a hotter day!
Its like driving the FJ Cruiser Dual VVTI V6 but in a much lighter chassi
Fuel economy improved enormously! This could be in part to the A/F sensor being positioned closer to the engine for faster processing - but its also due to the massive torque gain!!
Tacoma 2009-2011 Dual Skin Exhaust Manifold advantages
There is a reason why this design is used on the Aurion engine, is350 and the newer 1GR-FE Dual VVTI.
Yes the ticking is GONE and also that horrible restrictive air noise is gone but also the dual skin keeps the exhaust gases much hotter helping the cats work more effectively and also promote gas flow.
Much more environmentally friendly
The location of the A/F sensor closer to the engine enables faster ECU processing helping fuel economy and cleaner emissions. It has also stopped the tendency for the ECU with standard exhausts to "over compensate" with fuel when you floor the pedal or pull away hard from the lights - this has lead to some standard headers melting the cats!
Why did the USA get the better Headers and not Australia
California has some of the worlds toughest pollution rules so Toyota USA had to keep developing the 1GR-FE and as such the 2012+ now has EGR (these will not fit our engine) - plus they were beginning to lose sales to the Nissan Navara 200KW V6 Equivalent - by doing this it would put the Tacoma at 190KW but because its lighter its performance is better.
We did not get them I think due in part to they are more expensive to make and the fact Toyota Australia does not sell many V6's and our pollution laws are not as tough unfortunately for motor vehicles (so Holden and Ford could complete).
Tuned length & correct size pipe work for both Forced Induction & normally aspirated - bigger is not better
A lot of guys go too big on the pipe work of a naturally aspirated engines or too long on the "Primaries of Headers" and too big on the dump pipe of a Turbo and you lose exhaust velocity which in turn reduces or stops the scavenging effect -- or to put it another way the "Vacuuming Effect" that helps sucks out the cylinder ready for the next combustion cycle. Just as Turbo Charging has a massive effect on an engines performance by forcing air in; your exhaust plays a part in using the spent exhaust gases energy to help "Vacuum" out the other cylinders. You have all seen it - Honda Civics running bigger exhausts than a V8 Super car! You will lose HP and NW!!
The "Back Pressure Myth" or "Your engine has lost KW and NW because it needs cylinder filling via back pressure
The above exhaust system works because a lot of engineering calculations went into getting the pipe work size and length correct for the engine displacement and the RPM range that it operates in. Dont believe the "Myth" that 4 stroke engines require "Back Pressure" or the 1GR-FE needs back pressure for "Cylinder Filling" - this is wrong you need exhaust velocity for "Cylinder Filling" not "Back Pressure" and conversely going too big with pipe work will do the same thing. This is usually said (Back Pressure) by people who have no idea about Air Flow or exhaust systems - some will even try to then sell you a "Piggy Back" ECU to try and gain back your drop in Torque and HP after selling you their exhaust system.
I know this may be hard to believe but manufacturers do spend a lot of time on the exhaust engineering and I can assure you I had to do a lot of work to better the standard performance of the 1GR-FE Exhaust.
Engineering plays a big part in exhaust design and so many get it wrong thinking "Massive Pipes" or "Long Tube Headers".
If you are interested here is an Article on Exhaust Header Theory from Burns Stainless http://www.burnsstainless.com/theory.aspx
The example is there are plenty of 700hp Drag cars running only twin 2.5" pipes!
When you run the "correct size" pipe work and a "Tuned Length" on a V6 or V8 the scavenging effect is almost like supercharging (Ok not really) - But on a 600hp V8 it can be worth more than 30HP!
Just look above at the massive torque gain above - its everywhere!!
Oh and you also do correct size pipes and tuned length for the sound ----- so it doesn't sound like a V6 Crappydoor
What does it sound like
A lot like a European V6 and this is mainly due to the "Tuned Length" pipe work and Burns Stainless Steel Y Pipe.
The Borla mufflers do exactly what they said they would do "Turn the Volume down but up the Base" - Borla mufflers are world renowned for this and as such the Hilux has a wonderful burble under 2,000 RPM and at 1,500 RPM it could be mistaken for a V8.
The best part and one I did not expect is that its actually much quieter and its difficult to believe as the Borla mufflers are straight through - they do not contain baffles and as such almost have Zero change on the exhaust flow.
The above results are Dyno proven (with Toyota cats in place)
We have tried long tube headers and exhaust (naturally aspirated 1GR-FE) and they have resulted in a significant drop in HP and NW right where you need it most for a very poultry 7HP gain almost at redline - this has also been back up on other forums and also by people in the USA testing Long and Short Tube Extractors and various exhaust systems on the V6 Tacoma - most of these Extractors are the same as here and they are simply re-branded for us. Remember that you spend 99% of the time under 3,000RPM in a 1GR-FE V6 and any loss of KW and NW down low will destroy drive-ability and ruin fuel economy
Please dont believe bogus reports that some people make that long tube extractors will yield 30 + hp gains as this is simply not true on a naturally aspirated 1GR-FE V6 - but results may be different on Supercharged and Turbo engines.
Thank You
Advan Performance Centre for the use of their Dyno and Peters care with my Hilux
Best Exhaust - Thank You Mike for the advice on the Borla Mufflers
Burns Stainless Steel
Dallas Toyota
Performance Metalcraft - Leon's work was as good as my Aircraft Welder
And Philby for technical assistance and also having to hear me talk about supercharging it for the last 6 years
TRD actually does full testing and R&D 
